Process for preparing shaped product made of inorganic-organic composite material

ABSTRACT

A SHAPED ARTICLE FORMED FROM AN INORGANIC-ORGANIC COMPOSITE IS PREPARED BY ADMIXING AN INORGANIC POWDER, WHEREIN AT LAST 10% BY VOLUME OF SAID POWDER HAS A PARTICULATE DIAMETER OF LESS THAN 100U, WITH 0.3-20% BY WEIGHT OF AN AQUEOUS EMULSION OF EITHER A NON-CRYSTALLINE SYNTHETIC RESIN CHARACTERIZED BY A DEFORMATION TEMPERATURE OF HIGH ER THAN ROOM TEMPERATURE OR OF A CRYSTALLINE SYNTHETIC RESIN CHARACTERIZED BY A MELTING POUNT OF HIGHER THAN ROOM TEMPERATURE; SHAPING SAID MIXTURE AND HEATING TO AT LEAST THE DEFORMATION OR MELTING TEMPERATURE OF SAID SYNTHETIC RESIN AND THEREAFTER COOLING.

United States Patent 3,836,504 PROCESS FOR PREPARING SHAPED PRODUCT MADE OF INORGANIC-ORGANIC COMPOSITE MATERIAL Takao Morisawa, Yokkaichi, Japan, assignor to Mitsubishi Petrochemical Co., Ltd., Tokyo, Japan No Drawing. Filed Mar. 6, 1972, Ser. No. 232,274 Claims priority, application Japan, Mar. 6, 1971, 46/12,031 Int. Cl. C08f 45/04 US. Cl. 260-4255 8 Claims ABSTRACT OF THE DISCLOSURE A shaped article formed from an inorganic-organic composite is prepared by admixing an inorganic powder, wherein at least 10% by volume of said powder has a particulate diameter of less than 100 with 03-20% by weight of an aqueous emulsion of either a non-crystalline synthetic resin characterized by a deformation temperature of higher than room temperature or of a crystalline synthetic resin characterized by a melting point of higher than room temperature; shaping said mixture and heating to at least the deformation or melting temperature of said synthetic resin and thereafter cooling.

BACKGROUND OF THE INVENTION Field Of The Invention This invention relates to a process for preparing a shaped product preparedfrom an'inor'ganioorganic composite and characterized by. a high ratio ofinorganic material, and having high strength properties.

. Description Of Prior Art SUMMARY OF THE INVENTION Accordingly, it is orie object of this invention to provide a process whereby shaped articles having a high ratio of inorganic material and high strength properties, can be easily and'economically prepared using an inorganic-organic composite.

This and other objects of this invention can be attained by admixing fine particles of an artificial or natural inorganic material wheren at least 10% -by volume of said particles hasa particle diameter of less than 100 with an' aqueous emulsion of either a non-crystallinesynthetic resin, having a deforming temperature of higher than room temperature, or of a crystalline synthetic resin, having a melting point of higher than room temperature, wherein said emulsion comprises between 03-20 percent by weight, preferably 2-l0% by weight of said mixture.

The mixture is shaped, preferably by press-shaping, and then heated to a temperature of higher than the deforming or melting temperature of said synthetic resin, and. then is cooled.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT In accordance with the process of this invention, products having high strength properties and good chemical 3,836,504 Patented Sept. 17, 1974 resistance, similar to so-called thermosetting resin ceramics, are prepared easily and at an economic cost, comparable to the costs for producing cement products.

In preparing the products of this invention, no special apparatus or special skills are required other than those required for preparing mortar or cement. For instance, a conventional forced kneading mixer is sufficient for mixing the components of the products of this invention. Since high temperature treatment is not required, there is no need to provide high temperature kilns or furnaces.

Nevertheless, the resulting products of this invention have been found to have as much as 400% greater bending strength as mortar and are either incombustible or difficulty combustible and there is no restriction on the size of the products prepared, as there is for ceramics. Accordingly, the products of this invention can suitably be used as construction or building materials.

These products are prepared by combining fine sized inorganic particles With a synthetic resin which has either a specifically defined melting point or a specifically defined deforming temperature, in the form of an aqueous emulsion of an organic element. The mixture is heat treated, shaped and cooled.

A wide variety of inorganic materials can be used in this invention, such as fly ash, silica, kaolin, montmorillonite, clay,-volcanic pumice, glass powder, hollow glass beads, calcium carbonate, bentonite, titanium white, gypsum, calcium sulfite, blast furnace slag, cement, silica powder, etc. If the inorganic material is selected for its high chemical resistance or high water resistance, or high heat resistance, the ultimate product will have similar desirable properties. In general, the intended application and economic considerations will control the selection of the particular inorganic material to be used. It is quite an important factor of this invention to use the inorganic material in a particulate form, wherein at least 10% by volume of the particles has a diameter of less than 100,, preferably less than 50 in diameter. If more coarse particles are used in amounts of greater than by volume, the resulting composite product will not have the high strength characteristics of those products of the present invention. The more fine particles as defined above, are finely dispersed within the gaps of the more coarse particles and provide synergistic benefits when further admixed with the synthetic resin. It is preferable, but not mandatory, that less than of the particles used have diameters falling within the above fine particle definition. It is desirable for this purpose to admix a coarse aggregate with said compositionjsuch as sand or fine stone, in amounts of from 090% by volume.

Two or more different types of the inorganic particles can be used if desired.

The synthetic resin used for the process of this inven tion may be a thermoplastic resin, such as polyethylene, polypropylene, polyvinylchloride, polystyrene, polyacrylic esters, polyacrylonitrile, polyvinylidenechloride, polyvinylacetate, polyamide, polybutene, polyisobutene; copolymers of the monomers of said-resins, and blends of said resins, which have functional groups, such as those having carbonyl groups, epoxy groups, amino groups, groups, or vinyl groups.

If the resin is non-crystalline, it should have a deforming temperature of at least room temperature, or if it is a.

crystalline resin, it shouldha've a melting point of higher than-room temperature. Preferably, the deforming or melt-- strength of the resulting product, where the deforming temperature of melting point of the resin is too. low, it

will be difficult to obtain a product having sufiicient strength.

hydroxy 3 The synthetic resin is preferably used in amounts of less than 20 percent by weight, based on the total weight of the composite from the viewpoint of incombustibility or cost.

On the other hand, greater than 0.3 percent by weight (higher than 200 C.) for too long a period (more than 1 day), deterioration of the synthetic resin can result which can decrease the strength of the product. In order to prevent deterioration, it is possible to heat-treat the mixture in an inert gaseous atmosphere, in vacuo or under by removal of water.

The inorganic-organic composite can be shaped into any desired configuration, such as in the form of tubes, pipes, U-shaped grooves, piles, poles, cross-ties, arrowof synthetic resin is required to obtain high strength char- 5 high pressure to promote the heat treatment. acteristics. Preferably, the synthetic resin is used in Having now generally described the invention, a furamounts of from 2-10% by weight. The synthetic resin ther understanding can be obtained by reference to ceris used in the form of an aqueous emulsion with the intain specific Examples which are provided herein for purorganic element. poses of illustration only and are not intended to be The aqueous emulsion can also contain a minor porlimiting in any manner, unless otherwise specified. tion of water soluble resin, if a substantial amount of i resin is present in the dispersed phase. This emulsion can EXAMPLE 1 be prepared by conventional emulsion polymerization A fly ash having a diameter of 2-3;; was used as the techniques or by emulsifying a melted synthetic resin. inorganic material and a standard cement grade sand Suitable conventional emulsifiers may be used to obtain having a particulate diameter of 100-300; was admixed the emulsion. with the fly ash and an emulsion of a' copolymer of It is not fully understood why the use of an emulsion styrene-butylacrylate having a deforming temperature of will provide such exceptionally good results in binding about 80 C. which contains 12 percent by weight, based the composite product and providing good mixing. Howon the total of the inorganic and organic materials, was ever, it seems to be due to the manner in which the admixed therewith. The fluidity of the mixture was 130- synthetic resin is adhered to the surface of the inorganic 200 mm. of mortar flow value. r

particles. The emulsion preferably should be free of Or- The resulting mixture was pressed into amold to form ganic solvents, so that the flame potential or toxicity of bending a sheet of 4 x 4 x 16 cm. and was removed from the product is reduced. the mold after 1 or 2 days. The shaped material was It is preferred to use 3-30 percent by weight of water heat-treated for 10 days as shown in Table I. based on the inorganic material. Where the amount of The results of bending test measurements areshown in water is too small, workability and mixability of the com- Table I.

TABLE I Bending strength Tensile strength A Compressing g-fi m (kg/cm?) strength (kg/cm!) Composition (weight. percent) No heat Heat Result of No heat Heat No heat Heat Synthetic Inorganic Aggretreattreatdipping in treattreattreattreatresin materlal gate ment meat 20% H2SO4 ment ment ment ment 65 a5 68 35 25.6 No corrosion 10.5 69 61 as 10 114.9 d 4.2 46 27 an. 59 a5 19 242.3 d0 7.9 101 51 654 57 35 20 257.4 do 8.8 107 54 693 As the reference, the corresponding data of mortar was shown. position will be inadequate so that the dispersibility of the resin will be insufiicient. Where the amount of water Bending 5 5; used is too great, the degree of shrinkage occurring durs s st ing shaping can be deleterious and the ultimate strength -l gJem.) of the product can be adversely affected. Shaping can be 5 carried out by pressing the product into a suitable mold or by extrusion. Optionally, such shaping can be preceded EXAMP 2" In accordance with the process of Example 1, the same fly ash were varied. The results are shown in Table II.

TABLE II Bending strength Tensile strength Compressing (kg/cm?) (kg. cm?) strength (kg/cm!) Composition (weight percent) No heat Heat Result of N0 heat Heat N 0 heat Heat Synthetic Inorganic Aggretreattreatdipping 1n treattreattreattreatresin material gate meni; ment 20% H1804 ment. ment ment ment 74 20 10 127. 9 No corrosiom- 4. 2 58 27 307 59 19 24.3.3 do 7.9 101 51 583 4d 11 4. 6 60 30 344 29 7 2. 9 34 19 197 14 2. 9 26 151 Norm-Measurement could not be done. shaped piles, pillars, roof plates, bars, floor plates, wall I 65 EXAMPLE 3 plates, etc. or ocean development products.

In order to obtain a high strength product, it is necessary to heat-treat the mixture with or without decreasing the amount of water present. It is necessary that the temperature of heat treatment be higher than the deforming temperature if a non-crystalline resin is used or higher than the melting point if a crystalline resin is used and is preferably higher than 30 C. above the deforming temperature' or melting point. These temperatures should be maintained for more than 10 minutes.

In accordance with the process of Example 1, the same experiments were repeated exceptusing a mixture of standard cement grade sand of a particulate diameter of 70 100-300, as the aggregateand bentonite having a par- If the mixture is heat-treated at too high a. temperature 7 diameter of 30p.

The results are shown in Table III. or the melting point of the synthetic resin, and cooling TABLE III Compressing Banging strgigth Tensile/strength itrength g. cm. cm. m. Composition (wt. percent) No heat Heat Result of No heat Heat N heat Heat Synthetic Aggretreattreatdipping in treattreattrcattreatresin Inorganic material, item gate ment ment H2804 ment ment ment ment 150 No corrosion 63 360 0 180 do 75 432 64 190 Corrosion 16. 2 79 96 456 G4 00 ....,d0 6.4 37 144 EXAMPLE 4 said heated shaped mixture to obtain the shaped composite The inorganic material and aggergates shown in Exproduct ample 1 were admixed with an aqueous emulsion of a The plocess of Clalm Wherem the Shaped mate' copolymer of ethylene vinylacetate having a melting point 15 rial is heat-treated at a temperature of higher than of about 80 C. at the rate of 12 percent by weight of above th temperature the melting Point Water based on the total weight of solid, and then the of the synthetlc ms111- mixture was treated in accordance with the process of The Process of Claim wherein Said miXtllre of Example 1, inorganic powder and aqueous emulsion of synthetic resin TABLE IV Bending strength Tensile strength Compressing (kg/emf) (kg/em!) strength (kg/cm?) Com osition Wei ht ercent $4 No heat Heat Result of No heat Heat No heat Heat, Synthetic Inorganic Aggretreattreatdipping in treattreattreattreatresin material gate ment ment 20% H1804 ment ment ment ment 34 66 29 66 74.2 No corrosion 3 200 24 66 11.5 122.8 do 4.8 51 31 332 EXAMPLE 5 30 is shaped by compression so that the fine particles of said fiy ash will fill in the gaps between said coarse The inorganic material and aggregates shown in Exaggregate particles of sand together with said aqueous ample 1 were admixed With an aqueous emulsion of emulsion of said synthetic resin. polystyrene having a deforming temperature of 100 C. 4. The process of Claim 1 wherein the synthetic resin at the rate of 12 percent by weight of water based on the total weight of solid and then the mixture was treated is present in amounts of 2 to 10 percent by weight.

5. The process of Claim 1, wherein the aqueous emulin accordance with the process of Example 1. sion contains 3 to 30 percent by weight of water based TABLE V Bending strength Tensile strength Compressing strength (kg/em?) (kg. cm?) (kg/cm?) Composition (weight percent) Result of No heat Heat dipping No heat Heat No heat Synthetic Inorganic Aggretreattreatin 20% treattreattreat- Heat resin material gate ment ment H1504 ment ment ment treatment 34 66 29 66 44 105.8 286 No corrosion. 24 66 6. 3 so 15. 2 192. 7 41 521 Do.

As is clear in the results of the experiments, each of on the Weight of inorganic powder. the tensile, bending and compressive strength of the T Process 9 Clalm 1, Whefelll the aqueous emlll shaped product prepared by the process of this invention 15 an emulslon of a copolymer of y l 1 t are significantly hlh8f than that of prior art materials. 5 acry This is believed tr be a highly unpredictable result. The Process P Claim Wherem h P Having now fully described the invention it will be uct contains 8 weight percent of synthetic resin, 57 welght apparent to one of ordinary Skill in the that many percent of fly ash and 35 weight percent of cement grade sand. changes and modifications can be made thereto w1thout 8. The process of Claim 2, wherein the temperature depamng from the spmt or scope of the mventlon as set is maintained for more than 10 minutes during said heat forth herein. treatment.

Accordingly, what is claimed and intended to be covered References Cited l i gjo gz ibr preparing a shaped compos'te product UNITED STATES PATENTS l which comprises admixing an inorganic powder of a 3 2 5; fine n 1 combination of from 14 to 74 wt. percent flyash having a diameter of 2 to 3,u. and 80 to 20 wt. percent of an Foster 260 29'2N aggregate of cement grade sand having a particle diameter 97 467 10/1972 $321113; a 2 of 10 3 0/ w a suflicient quantity of an aqueous 2,592,147 4/1952 Ikeda 26041B emulsion of non-crystalline synthetic resin se ected om 2,597,872 5/1952 Iler 260-41 A the group consisting of styrene-butylacrylate, polystyrene 3,421,277 1/1969 Frischmuth 26029.6 ME and ethylene-vinylacetate having a deforming tempera- 3,706,696 12/1972 Bernett 26029.6E

ture or a crystalline synthetic resin having a melting point higher than room temperature to produce a shaped com- ALLAN LIEBERMAN, Primary Examiner posite containing from 0.3 to 20 percent of synthetic P, R MIcI-IL, Assistant Examiner resin by weight based on the total weight of the composite, shaping said mixture, heat-treating said shaped mixture at a temperature higher than the deforming temperature 26() 37 N 342 42 4 4247, 4248 4249, 4252, 42 

